Metal fence posts with insulating couplers and associated systems and methods

ABSTRACT

Some embodiments are directed to multi-piece fence posts that include: (a) a first anchor (typically metal) fence post member having opposing first and second end portions, wherein, in position, the first end portion is configured to reside underground; (b) a second (typically metal) fence post member having opposing first and second end portions; and (c) a coupler configured to snugly hold the second end portion of the first anchor metal fence post member and the first end portion of the second metal fence post member to thereby define an elongate fence post.

RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Patent Serial No. 60/805,244, filed Jun. 20, 2006, the contents of which are hereby incorporated by reference as if recited in full herein.

FIELD OF THE INVENTION

The present invention relates to fences, and may be particularly suitable for multi-purpose fencing systems that can be used to hold a variety of different fencing materials.

BACKGROUND OF THE INVENTION

Plastic fence posts have been used to hold lateral fencing material such as wire, rope and/or fabric strips. Unfortunately, exposure to sun and/or other environmental elements can unduly deteriorate the plastic fence posts over time.

SUMMARY OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention provide multi-piece metal fence posts with insulating couplers therebetween.

The insulating couplers may define two opposed receiving channels and may have a substantially rigid elastomeric body. The receiving channel may comprise a planar portion to snugly and matably receive a metal fence post having a corresponding planar portion to provide positive orientation upon assembly.

Some embodiments are directed to multi-piece fence posts that include: (a) a first anchor (typically metal) fence post member having opposing first and second end portions, wherein, in position, the first end portion is configured to reside underground; (b) a second metal fence post member having opposing first and second end portions; and (c) an insulating coupler configured to snugly hold the second end portion of the first anchor metal fence post member and the first end portion of the second metal fence post member to thereby define an elongate fence post.

Other embodiments are directed to non-metallic insulating fence post couplers that are sized and configured to hold two metallic rods in spaced apart alignment.

The insulating coupler may include a partition residing between spaced apart first and second receiving channels to prevent the two metallic rods from contacting when assembled.

Still other embodiments are directed to a fencing system that includes: (a) a plurality of metal fence posts, at least some of which comprise first and second metallic fence post rod members held in spaced apart alignment by a non-metallic insulating coupler; (b) a plurality of fencing material couplers mounted on the metal fence posts; and (c) flexible material held by the fencing material couplers so as to extend between the metal fence posts to enclose a target area.

Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the embodiments that follow, such description being merely illustrative of the present invention. These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a digital image of an exploded front view of an exemplary multi-component fence post according to embodiments of the present invention.

FIG. 2 is a digital image of a lower portion of the fence post shown in FIG. 1 inserted into the ground.

FIG. 3 is a digital image of the fence post shown in FIG. 1 shown assembled and in position in the ground.

FIG. 4A is a front view of a insulating coupler used in the fence post shown in FIG. 1 according to embodiments of the present invention.

FIG. 4B is an end view of the coupler shown in FIG. 4A.

FIG. 4C is a sectional view of the coupler shown in FIG. 4B taken along line C-C thereof.

FIG. 5 is a sectional view of an alternate embodiment of an interior partition portion of an insulating coupler according to some embodiments of the present invention.

FIG. 6 is a schematic illustration of an end view of a metal fence post member according to some embodiments of the present invention.

FIG. 7 is an exploded view of a multi-component fence post according to embodiments of the present invention.

FIGS. 8-17 are digital images that illustrate different examples of fencing couplers and fencing material that can be used with fencing posts according to embodiments of the present invention.

FIG. 18 is an enlarged view of a fence post with a releasable mounted fencing material coupler according to embodiments of the present invention.

FIG. 19A is a schematic illustration of a fencing system according to embodiments of the present invention.

FIG. 19B is a schematic illustration of another fencing system according to embodiments of the present invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. Broken lines illustrate optional features or operations unless specified otherwise.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention. The sequence of operations (or steps) is not limited to the order presented in the claims or figures unless specifically indicated otherwise.

Turning now to the figures, FIG. 1 illustrates an exemplary fence post 10 with first and second metallic fence post members 15, 25, respectively, and an electrically insulating coupler 20 configured to hold each of the fence post members 15, 25. The coupler 20 is configured to inhibit electrical conductivity or transmission between the metallic fence post members 15, 25. The term “fence post” is used broadly to encompass fence posts used to hold any target material and can form a fence that encloses an area as well as a support structure that can hold a single or multiple strands of fencing material for allowing structural support for tarps, clothing, towels, vines, flowers, trees, fruits, vegetables and the like. The lower member 15 can be the anchor member and may include at least one tapered end portion 15 e for ease of implanting into target media such as soil or other subsurface anchoring location. Elastomeric “socks” 17 may be configured to conform and reside on the end portions 15 e. As shown, the anchor member 15 may include a fork configuration 16 for added stability with one prong 15 ₁ being longer than the other 15 ₂ and the longer member 15 ₁ may be substantially aligned with the upper portion of the member 15.

FIG. 2 illustrates the anchor member 15 in an assembled upright position. The fork orientation 16 may be inserted into the anchoring media in any desired orientation, i.e., so that the short member 15 ₂ is to the left, to the right to the front or back. Other achoring configurations may be used. Further, different fence posts 10 may be inserted using different orientations, such as, for example, adjacent fence posts 10 can be inserted into anchoring media so that the respective “short prong” 15 ₂ has a different orientation from others (see, e.g., FIG. 8).

FIG. 3 illustrates the fence post 10 in an exemplary position. As shown, the second fence member 25 can be greater than twice as long as the anchor member 15, and in some embodiments, can be between about 3-4 times as long.

FIGS. 4A-4C illustrate an exemplary insulating coupler 20. As shown in FIG. 4A, the coupler 20 can include first and second receiving channels 21, 22 separated by a partition 23 that inhibits the ends of the fence members from contacting each other when held by the coupler 20. The term “partition” refers to a configuration that spatially and/or electrically separates the ends of two fence members 15, 25 (or members 25 ₁, 25 ₂ as shown in FIG. 7) when held in the coupler 20. The partition 23 may close or occlude the entire region between the channels 21, 22. The partition 23 can have a thickness of between about 0.01-0.1 inches or other suitable thickness. Alternatively, the partition 23 may be configured to partially close the intermediate region and/or define a shelf 20 s (FIG. 5) that prevents the associated fence post member 15, 25 from sliding deeper into the coupler 20. In other embodiments, the coupler 20 may be open and the length of the coupler 20 and/or a tapering or other configuration of the channels 21, 22 (and/or the entering portion of the rod 15, 25) can be sufficient to inhibit contact. In still other embodiments, the ends of the fence post members 15, 20 in the channels 21, 22 can include a non-metallic end cap or integral component to electrically isolate the two members from each other in the coupler 20 (not shown). The receiving channels 21, 22 of a respective coupler 20 can have the same shape and length or different shapes and/or lengths.

As shown in FIG. 4C, the length of channel 22 can be longer than that of channel 21, typically between about 10-30% longer than channel 21. As shown in FIG. 4B, the channels 21, 22 can have at least one substantially planar portion 24 p (shown as two in FIG. 4B) connected by arcuate portions 24 a. The planar portion(s) 24 p of the first channel 21 may align with the second channel 22 or may be offset by between about 10-90 degrees (not shown). The shape of the fence post member 15, 25 and the respective receiving channel 21, 22 of the coupler 20 can be such to inhibit rotation (i.e., an anti-rotation configuration) after assembly and/or provide positive alignment for assembly. The portion of the fence member 15, 25 matably received in the channel (21, 22) can have a corresponding shape, as shown for example in FIG. 6. Other anti-rotation configurations may be employed, such as for example, a key and slot configuration and the like.

Referring again to FIG. 4B, the outer diameter of the coupler 20 can be about 0.50 inches, the wall inner diameter can be about 0.30 inches, and the distance “D” of the gap spacing the two substantially planar surfaces 24 p can be about 0.25 inches.

Referring to FIG. 4C, in particular embodiments, the length L₁ can be about 1.57 inches, while the length L₃ can be about 3.20 inches, and L₂ can be between about 1.65 to about 1.58 inches, and the coupler partition can have a thickness of between about 0.1 to about 0.05 inches.

The insulating coupler 20 can be non-metallic or may be metallic with non-metallic portions or coatings sufficient to electrically insulate the two metal fence post members 15, 25 after assembly and provide the desired structural support. In some embodiments, the coupler 20 is a unitary body of substantially rigid non-metallic material. The coupler 20 may be a molded body. Examples of suitable non-metallic materials include elastomers, composites and ceramics and/or combinations thereof, such as for example, polymers, copolymers and derivatives thereof such as nylon, acetal, polyethylene (PE), high-density molecular weight polyethylene (HDMWPE), and TEFLON.

FIG. 7 illustrates that the fence post 10 can include a plurality of upper metal fence post members 25 ₁, 25 ₂ and a plurality of couplers 20 ₁, 20 ₂ configured to hold the fence post 10 together. The different fence post members 25 ₁, 25 ₂ may have different lengths and different configurations or the same lengths and the same configurations. Similarly, the couplers 20 ₁, 20 ₂ can have the same lengths and/or configuration or may have different lengths and configurations. The fence post members 15, 25 may comprise a rod that may be a solid metal rod. In some embodiments, as shown in FIG. 6, the cross-sectional profile of the end portion of the member 15, 25 entering the channel of the coupler can have planar portions 125 p and arcuate portions 125 a. Thus, in some embodiments, at least the end portions of the rods 15, 25 that enter the coupler 20 (or 20 ₁, 20 ₂, FIG. 7) may have the same shape and size, such as the shape shown in FIG. 6.

The coupler 20 can be configured to slidably receive and releasably securely hold the fence post members 15, 20 (and/or 20 ₁, 20 ₂, FIG. 7). The releasable mounting allows for field replacement without requiring that the entire fence post 10 be replaced and/or without requiring the anchoring portion of the fence post 15 to be pulled from the ground or other supporting media.

In other embodiments, adhesive may be used to hold the coupler 20 and the respective fence post member 15, 20 (or 20 ₁, 20 ₂) in snug/tight abutment.

As noted above, the fence post members 15, 25 can be generally or substantially tubular with a non-circular shaped configuration, with a width that may be between about 0.1-1 inch, typically between about 0.2-0.5 inches, and at least one of the fence post members (e.g., member 25) is typically a solid metallic rod. In some embodiments, the fence member 15, 25 can be include a solid rod with a thickness of between about 0.25 inches measured across the planar portions (FIG. 6). In other embodiments, the member 15, 25 can be hollow or a solid or fluid filled with air or other core material.

Alternatively, circular tubular configuration posts may also be used. The fence member 15, 25 (i.e., rod) may be coated with a paint or other suitable material. Where non-metallic components are used, those components may be coated with or formed from an ultra-violet radiation-resistant material to allow for longer exposure to sun without undue deterioration.

FIGS. 8-18 illustrate that the fence posts 10 can accommodate a number of different fencing couplers 50 as well as a number of different fencing materials 75 providing a number of different build options at the user's specification. The multi-piece fence post 10 shown in FIG. 1 may be used with a single-piece metallic fence post 100, such as shown for example in FIG. 8. The couplers 50 can be pushed or slid onto the respective fence post 10, 100 and held in the desired location (shown as proximate an upper portion of member 25) by frictional interference and/or compressive engagement. In some embodiments, a number of different couplers 50 can mount to the same fencing post member 25, thereby providing build options suitable for a user. Also, the couplers 50 can be changed out with different material 75 over time. The configurations of the fence posts 10 and/or couplers 20, 50 provide both building flexibility and relatively rapid and easy installation.

In some embodiments, the fence posts 10 can be configured to hold fencing material 75 that may be flexible material. The term “flexible” means non-rigid (i.e., unlike boards). The fencing material 75 may comprise a substantially planar or other fabric, a tubular (drawn) relatively thin wire (smooth or barbed), rope, wire or rope, shielded wire, and the like. A fence post 10, 100 may also hold combinations of the different fencing materials.

In some embodiments, non-metallic, typically resilient, end caps 30 (FIG. 8) may be placed over each exposed tip (of each member 15, 25) for shipping and/or use.

FIG. 19A illustrates that multiple couplers 50 can be mounted to the fence posts 10 to provide a fence system 10 s with multiple levels of fencing material 75 that extends about and “encloses” an area. FIG. 19B illustrates that the fence system 10 s′ may alternatively be used to provide support for desired functions, such as drying or airing clothing and/or supporting vines, plants and the like as discussed above.

In some embodiments, the fence system 10 s can be used to provide an electric charge along the fencing material, e.g., an electric fence system.

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein. 

1. A multi-piece fence post comprising: a first anchor fence post member having opposing first and second end portions, wherein, in position in the ground, the first end portion is configured to reside underground; a second fence post member having opposing first and second end portions; and a insulating coupler configured to snugly hold the second end portion of the first anchor metal fence post member and the first end portion of the second metal fence post member to thereby define an elongate fence post.
 2. A fence post according to claim 1, wherein the first and second fence post members are metal, and wherein the insulating coupler that has spaced apart first and second receiving channels, each of the channels configured to snugly slidably receive and releasably hold a respective one of the first and second fence post members.
 3. A fence post according to claim 2, wherein the insulating coupler comprises a partition residing between the first and second receiving channels to prevent proximately held ends of the first and second fence members from contacting when assembled.
 4. A fence post according to claim 2, wherein the insulating coupler comprises a closed partition residing between the first and second receiving channels to prevent the proximately held portions of the first and second fence members from contacting when assembled.
 5. A fence post according to claim 1, wherein the first and second fence post members comprise metal rods.
 6. A fence post according to claim 5, wherein the metal rods have a cross-sectional profile with opposing first and second substantially planar portions connected by first and second opposing substantially arcuate portions, and wherein the insulating coupler is configured with at least one substantially corresponding receiving channel shape configured to matably and snugly receive target end portions of the first and second fence post members.
 7. A fence post according to claim 6, wherein the metal rods have a diameter that is between about 0.3 to about 0.5 inches, measured from a centerline extending across the metal rod to the arcuate portions.
 8. A fence post according to claim 2, wherein one of the first and second channels is longer than the other.
 9. A fence post according to claim 8, wherein the longer channel is between about 10-30% longer than the other channel.
 10. A fence post according to claim 2, wherein the insulating coupler is non-metallic.
 11. A fence post according to claim 1, further comprising at least one non-metallic fencing material coupler configured to slidably mount to the second fence post member to releasably hold fencing material.
 12. A fence post according to claim 1, further comprising a plurality of non-metallic fencing material couplers configured to releasably hold flexible, substantially planar fencing material.
 13. A fence post according to claim 1, further comprising a plurality of non-metallic fencing material couplers configured to releasably hold a strip of wire.
 14. A fence post according to claim 11, wherein the non-metallic fencing material couplers are configured to hold the fencing material in a substantially horizontal orientation.
 15. A non-metallic insulating fence post coupler sized and configured to hold two metallic rods in spaced apart alignment.
 16. A coupler according to claim 15, wherein the insulating coupler comprises a partition residing between spaced apart first and second receiving channels to prevent the two metallic rods from contacting when assembled.
 17. A coupler according to claim 16, wherein the insulating coupler comprises a closed partition residing between the first and second receiving channels to prevent proximately held ends of the two rods from contacting when assembled.
 18. A coupler according to claim 15, wherein the receiving channels have a cross-sectional profile with opposing first and second substantially planar portions connected by first and second opposing substantially arcuate portions.
 19. A fence post according to claim 16, wherein one of the first and second channels is between about 10-30% longer than the other channel.
 20. A fencing system comprising: a plurality of metal fence posts, at least some of which comprise first and second metallic fence post rod members held in spaced apart alignment by a non-metallic insulating coupler; a plurality of fencing material couplers mounted on the metal fence posts; and flexible material held by the fencing material couplers so as to extend between the metal fence posts to enclose a target area. 